Senior Controls and Automation Engineer
s s cycleViola (WI)
About the role
Job Description:
Job Description POSITION TITLE: Senior Controls and Automation EngineerDEPARTMENT: EngineeringREPORTS TO: Engineering ManagerLOCATION: ViolaJOB SUMMARY:A Senior Controls & Automation Engineer to design, build, and support custom automated test equipment, manufacturing systems, and embedded control solutions for powertrain development and production support. This role bridges industrial automation, embedded hardware/firmware, and system integration, supporting everything from robotic test cells and PLC-controlled machinery to ECU-integrated embedded devices and Windows-based engineering tools. The ideal candidate is a hands-on engineer comfortable working across electrical design, firmware, PLCs, robotics, HMIs, and on-site commissioning of one-off and low-volume systemsESSENTIAL FUNCTIONS:Industrial Automation & Controls Design, modify, and maintain automated test stands, endurance systems, and manufacturing equipment Program and troubleshoot PLCs and HMIs for presses, test fixtures, and special-purpose machinery Integrate industrial robots with presses and test systems, including interlocks and safety logic Retrofit and modernize legacy equipment where original electronics or controls are obsolete Support and repair custom, one-off automation equipment used in engineering and manufacturing Embedded Hardware & Firmware Design custom embedded control hardware for test systems and product prototypes Develop firmware in C/C++ for microcontroller-based controllers Implement CAN bus communication with ECUs and vehicle subsystems Create embedded solutions for sensors, actuators, motor control, and data acquisition Support prototype development through testing, iteration, and limited production readiness Test Systems & Instrumentation Develop automated engine and motorcycle test systems for endurance, EPA mileage accumulation, and performance testing Build systems for dyno automation, robotic control, and long-duration unattended operation Integrate sensors, cameras, and data acquisition hardware for mechanical and powertrain analysis Develop data visualization and processing tools for test and lab environments Software & Interfaces Develop Windows-based engineering and test applications (Visual Studio / C#)Interface off-the-shelf HMIs and custom hardware for operator control and remote monitoring Support configuration and calibration tools for embedded and test systemsECU & System Integration Integrate and interface with automotive ECUs, including CAN messaging and control features Support ECU feature development and experimentation for R&D projects Work closely with engineering and manufacturing teams to support powertrain development Reverse engineer CAN bus data in order to interface various ECUs with custom test equipmentQUALIFICATIONS:Bachelor's degree in Electrical Engineering, Computer Engineering, Mechatronics, or equivalent experience 5+ years experience in industrial automation, controls engineering, or custom machinery Strong experience with: PLC programming and industrial I/OEmbedded firmware development (C/C++)Electrical schematics and hardware design, PCB layout. Sensors, actuators, motors, VFDs, and safety circuits Hands-on experience commissioning and troubleshooting machines in real-world environments
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